Exhaust system having a gold-platinum group metal catalyst

ABSTRACT

A method of providing an exhaust treatment device is disclosed. The method includes applying a catalyst including gold and a platinum group metal to a particulate filter. The concentration of the gold and the platinum group metal is sufficient to enable oxidation of carbon monoxide and nitric oxide.

CLAIM FOR PRIORITY

The present application is a divisional of U.S. application Ser. No.12/318,002, filed Dec. 19, 2008, now pending, which is hereby fullyincorporated by reference.

GOVERNMENT RIGHTS

This invention was made with Government support under the terms of theOxidation CRADA, Contract No. PNNL230 awarded by the Department ofEnergy. The Government may have certain rights in this invention.

TECHNICAL FIELD

The present disclosure relates generally to an exhaust system and, moreparticularly, to an exhaust system having a gold-platinum group metalcatalyst.

BACKGROUND

Internal combustion engines such as, for example, diesel engines,gasoline engines, natural gas engines, and other engines known in theart, exhaust a complex mixture of chemical pollutants. The chemicalpollutants may include solid particulate matter, including hydrocarbon,and gaseous compounds, which may include nitrogen oxides (NOx) andcarbon monoxide (CO). Due to increased attention on the environment,exhaust emission standards have become more stringent, and the amount ofpollutants emitted to the atmosphere from an engine may be regulateddepending on the type of engine, size of engine, and/or class of engine.

One method that has been implemented by engine manufacturers to complywith the regulation of particulate matter exhausted to the environmenthas been to remove the matter from the exhaust flow of an engine withparticulate filters. However, over time the particulate matter builds upin the filter medium, thereby reducing functionality of the filter andsubsequent engine performance. To reduce the buildup of particulatematter and return functionality to the filter and engine, theparticulate trap is periodically regenerated. Regeneration involvesoxidizing, or combusting, the particulate matter, and is often achievedby increasing the temperature within the particulate filter with a fuelpowered burner or an electrical grid. Although this method is generallysuccessful, the combustion of the particulate matter, particularlyhydrocarbon, in oxygen requires high combustion temperatures ofapproximately 600-700° C. Because these temperatures typically exceedthe operating temperature of a diesel engine, in order to improveregeneration, it may be desirable to reduce the temperature at which thehydrocarbon combusts.

One method of reducing the combustion temperature of particulate matteris disclosed in U.S. Pat. No. 4,902,487 (the '478 patent), issued toCooper et al. The '478 patent discloses a method of providing nitrogendioxide (NO₂) to the particulate matter in order to reduce thecombustion temperature of the particulate matter. The method includespassing exhaust gas through a catalyst coated with platinum or anotherplatinum group metal, so that nitric oxide (NO) in the exhaust gas iscatalytically converted to NO₂. The NO₂ is fed to the particulate filterwhere the particulate matter is combusted in a temperature range of250-400° C.

Although the method of the '478 patent may reduce the combustiontemperature of particulate matter, the temperature range required forregeneration may still exceed the operating temperature of the engine.In order to improve regeneration, it may be desirable to further reducethe combustion temperature.

The disclosed exhaust system is directed to overcoming one or more ofthe shortcomings set forth above and/or other shortcomings in the art.

SUMMARY

In one aspect, the present disclosure is directed to a method ofproviding an exhaust treatment device. The method includes applying acatalyst including gold and a platinum group metal to a particulatefilter. The concentration of the gold and the platinum group metal issufficient to enable oxidation of carbon monoxide and nitric oxide.

In another aspect, the present disclosure is directed to an exhausttreatment device. The exhaust treatment device includes a gold-platinumgroup metal catalyst configured to increase a concentration of nitrogendioxide, decrease a concentration of carbon monoxide, and reduce anoxidation temperature of hydrocarbon.

In yet another aspect, the present disclosure is directed to a method ofoperating an exhaust treatment device. The method includes exposing aflow of exhaust to a gold-platinum group metal catalyst and decreasing aconcentration of carbon monoxide within an exhaust stream. The methodmay also include increasing a concentration of nitrogen dioxide withinan exhaust stream and oxidizing hydrocarbon within an exhaust stream.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagrammatic illustration of a power source having anexhaust system according to an exemplary disclosed embodiment.

DETAILED DESCRIPTION

FIG. 1 illustrates an exemplary power source 10. The power source 10 mayinclude an engine 11 such as, for example, a diesel engine, a gasolineengine, a gaseous fuel-powered engine, or any other engine known in theart. The power source 10 may, alternatively, include a non-engine sourceof power such as a furnace. The power source 10 may include an exhaustsystem 16 that directs exhaust away from the engine 11.

The exhaust system 16 may include components that direct and/or treatexhaust from the engine 11. In particular, the exhaust system 16 mayinclude a filter system 32 and an exhaust outlet 34. The exhaust fromthe engine 11 may pass through the filter system 32 to the exhaustoutlet 34 before discharge to the atmosphere. It is contemplated thatadditional emission-controlling devices may be included within theexhaust system 16, if desired.

The filter system 32 may be placed downstream of the engine 11 to removeparticulates, including hydrocarbon, from the exhaust and catalyzegaseous compounds. The filter system 32 may include a particulate filter40 and a catalyst 42.

The particulate filter 40 may remove particulate matter from theexhaust. The particulate filter 40 may include, for example, a foammaterial. The foam material may be formed from sintered metallicparticles such as, for example, alumina, titania, or any otherhigh-temperature alloy. The foam material may also be formed fromceramic particles such as, for example, silicon carbide, cordierite,mullite, or any other ceramic particles known in the art. The foammaterial may be formed into a filter medium through a casting process,an injection molding process, or any other process that produces aporous material with a desired porosity. Alternatively, the filter 40may include a monolith substrate in which the exhaust is forced throughthe walls of the substrate by alternatively blocking inlet and exitchannels, in a manner known in the art. The monolith substrate may beformed from ceramic material such as cordierite, or from a suitablemetal.

The catalyst 42 may be incorporated throughout the particulate filter 40and may be configured to oxidize CO and NOx to enable low temperaturecombustion of hydrocarbon within the particulate filter 40. The catalyst42 may be a gold and platinum group metal alloy. The platinum groupalloy may be, for example, ruthenium, rhodium, palladium, osmium,iridium, or platinum. The catalyst 42 may be applied as a wash coatingto the particulate filter 40 or incorporated into the filter material inany other manner known in the art. The catalyst 42 may be, for example,gold-palladium (Au—Pd) with a composition of between about 0.08% and1.2% Au and between about 0.4% and 0.6% Pd, by weight, on a titania(TiO₂) support. For example, catalyst 42 comprise between about 0.9% andabout 1.1% Au and between about 0.45% Pd and about 0.55% Pd by weight,such as about 1.0% Au and about 0.5% Pd. The catalyst 42 may enable lowtemperature combustion of hydrocarbon by achieving lightoff, that is,oxidation of about 50% of the CO present, at a temperature of about 60°C. The catalyst 42 may also oxidize NOx to form NO₂, and may achievelightoff of NOx at about 230° C. By reducing the concentration of CO inthe exhaust gas and increasing the concentration of NO₂, the catalyst 42may enable the hydrocarbon within the particulate filter to combust atabout 206° C.

INDUSTRIAL APPLICABILITY

The disclosed exhaust treatment system may be applicable to anycombustion-type device, such as an engine or a furnace, where thecombustion of hydrocarbon within an exhaust stream thereof is desired.The disclosed exhaust treatment system may reduce a concentration of COin an exhaust stream, while increasing a concentration of NO₂. Theresultant gas may facilitate combustion of hydrocarbon at reducedtemperatures, and improve particulate filter regeneration. Operation ofthe exhaust treatment system 16 will now be explained.

Atmospheric air may be drawn into a combustion chamber of the engine 11.Fuel may be mixed with the air before or after entering the combustionchamber. This fuel-air mixture may be combusted by the engine 11 toproduce mechanical work and an exhaust flow including hydrocarbon, CO,NOx, and other solid and gaseous compounds.

The exhaust gas flow may be directed to the filter system 32 wherehydrocarbon and other particulate matter entrained with the exhaust flowmay be filtered by the particulate filter 40. As the exhaust gas passesthrough the particulate filter 40, CO and NOx gases may be exposed tothe catalyst 42. The catalyst 42 may be composed of gold-palladium andmay oxidize CO and NOx present in the exhaust to form CO₂ and NO₂,respectively.

The gold-palladium catalyst 42 may be more efficient than using either agold or a palladium catalyst alone, as is typically done. Specifically,the gold-palladium catalyst may achieve a CO to CO₂ conversion attemperatures lower than those possible with gold alone. For example, thegold-palladium catalyst 42 may convert 90% of the CO present in theexhaust to CO₂ at about 84° C., where as a gold catalyst alone mayrequire a temperature of about 105° C. to convert the same amount ofCO₂. Because the gold-palladium catalyst 42 may convert CO to CO₂ atlower temperatures, the reaction may require less energy, and thus, bemore efficient than a gold catalyst.

Increasing CO₂ may have the added advantage of requiring less platinumgroup metal than is typically used to catalyze NOx. Specifically,reducing the concentration of CO in the vicinity of the platinum groupmetal may reduce the magnitude of CO poisoning of the platinum groupmetal. Typically, countering CO poisoning of platinum group metalcatalysts is achieved by the use of excess platinum group metal, whichmay be costly. Thus, by reducing the effect of CO poisoning on theplatinum group metal, the gold-palladium catalyst 42 may maintain itseffectiveness in converting NOx to NO₂ within particulate filter 40without the use of excess costly material.

Due to the increased concentration of NO₂ and decreased concentration ofCO, lightoff of the particulate matter may be achieved at a temperatureof about 165° C., and 90% of the particulate matter may be oxidized at atemperature of about 206° C., which may be within an operatingtemperature of the engine 11. Because regeneration may be achieved attemperatures within the operating range of the engine 11, i.e. withinthe temperature range of exhaust from the engine 11, the need forproviding external energy in the form of electricity or fuel may bereduced or eliminated, and the efficiency of the regeneration event maybe increased.

The exhaust treatment system 16 of the present disclosure may reduce aconcentration of CO in an exhaust stream while increasing aconcentration of NO₂. The resultant exhaust gas may facilitatecombustion of hydrocarbon at reduced temperatures, and thus increase theefficiency of particulate filter regeneration. Furthermore, thedisclosed exhaust treatment system may reduce the CO poisoning ofplatinum group metals within the catalyst 42, thereby reducing the costof the exhaust treatment system.

It will be apparent to those skilled in the art that variousmodifications and variations can be made to the exhaust treatmentsystem. Other embodiments will be apparent to those skilled in the artfrom consideration of the specification and practice of the disclosedexhaust treatment system. It is intended that the specification andexamples be considered as exemplary only, with a true scope beingindicated by the following claims and their equivalents.

1. A method of providing an exhaust treatment device including applyinga catalyst including gold and palladium to a particulate filter, whereinthe catalyst contains between about 0.8 and 1.2% Au and between about0.4 and 0.6% Pd, by weight.
 2. (canceled)
 3. A method of providing anexhaust treatment device including applying a catalyst including goldand palladium to a particulate filter, wherein applying the catalystincludes applying a catalyst containing between about 0.8 and 1.2% Auand between about 0.4 and 0.6% Pd, by weight, and the balance titania.4.-13. (canceled)
 14. A method of operating an exhaust treatment device,comprising: exposing a flow of exhaust to a gold-platinum group metalcatalyst, wherein the catalyst contains between about 0.8 and 1.2% goldand between about 0.4 and 0.6% palladium, by weight; and at least one ofdecreasing a concentration of carbon monoxide within the exhaust stream,increasing a concentration of nitrogen within the exhaust stream, andoxidizing hydrocarbon within the exhaust stream.
 15. (canceled)
 16. Amethod of operating an exhaust treatment device, comprising: exposing aflow of exhaust to a gold-platinum group metal catalyst, wherein thecatalyst contains between about 0.8 and 1.2% gold and between about 0.4and 0.6% palladium, by weight, on a titania support; and at least one ofdecreasing a concentration of carbon monoxide within the exhaust stream,increasing a concentration of nitrogen within the exhaust stream, andoxidizing hydrocarbon within the exhaust stream.
 17. (canceled)
 18. Themethod of claim 14, wherein decreasing the concentration of carbonmonoxide includes oxidizing carbon monoxide at a temperature of about84° C.
 19. The method of claim 14, wherein increasing the concentrationof nitrogen includes oxidizing nitrogen oxide to form nitrogen dioxide.20. The method of claim 14, wherein oxidizing the hydrocarbon includesoxidizing hydrocarbon at about 206° C.
 21. The method of claim 1,further including: decreasing a concentration of carbon monoxide in anexhaust stream flowed over the catalyst by oxidizing the carbon monoxideat a temperature of about 84° C.
 22. The method of claim 1, furtherincluding: increasing a concentration of nitrogen in an exhaust streamflowed over the catalyst by oxidizing nitrogen oxide to form nitrogendioxide.
 23. The method of claim 1, further including: flowing anexhaust stream over the catalyst to oxidize hydrocarbon in the exhauststream at about 206° C.
 24. The method of claim 3, further including:decreasing a concentration of carbon monoxide in an exhaust streamflowed over the catalyst by oxidizing the carbon monoxide at atemperature of about 84° C.
 25. The method of claim 3, furtherincluding: increasing a concentration of nitrogen in an exhaust streamflowed over the catalyst by oxidizing nitrogen oxide to form nitrogendioxide.
 26. The method of claim 3, further including: flowing anexhaust stream over the catalyst to oxidize hydrocarbon in the exhauststream at about 206° C.
 27. The method of claim 16, wherein decreasingthe concentration of carbon monoxide includes oxidizing carbon monoxideat a temperature of about 84° C.
 28. The method of claim 16, whereinincreasing the concentration of nitrogen includes oxidizing nitrogenoxide to form nitrogen dioxide.
 29. The method of claim 16, whereinoxidizing the hydrocarbon includes oxidizing hydrocarbon at about 206°C.